Fastener devices

ABSTRACT

A fastener adapted to be set in a body of concrete to facilitate the later attachment of utilities such as pipes, brackets, ducts and the like. The fastener is adapted to be temporarily secured to formwork prior to a concrete pour and once concrete is cured, the formwork can be readily released from the fastener.

FIELD OF INVENTION

This invention relates to fastener devices and in particular, to devices used to support utilities such as pipes, cable racks, ducting and the like, or fixtures or fittings, suspended from or adjacent to concrete floors, walls and columns in a structure.

BACKGROUND ART

At present on construction sites and in particular large multistorey buildings with concrete floors, columns and walls, follow-up trades have the tedious and time consuming task of drilling holes into the concrete structure in order to secure fastening devices so that they can install utilities according to specifications.

The task is particularly difficult when there is a requirement to secure utilities to an overhead concrete floor requiring the use of ladders on elevated planks or scaffolds. This task is also particularly messy as the drilling required results in a large amount of debris showering down onto the person using the drill.

Most building construction is carried out by independent trades and this is particularly the case for high rise constructions comprising concrete columns and concrete floors. Once floor formworks have been placed and reinforcing laid, there is the opportunity for other trades to set anchors or fasteners for embedding in the concrete floor in order to secure fittings such as cables, pipes, ducts and the like once the floor has been poured and the formwork removed.

European patent application no. 88301377.3 and Japanese patent application no. 2001-233085 are examples of inserts for embedding in concrete for the convenience of following trades. In both cases however, the positioning of the inserts involves drilling holes in the formwork in order to secure the inserts prior to concreting and thus rendering the formwork unusable for ongoing construction works.

BRIEF DESCRIPTION OF THE INVENTION

According to a first aspect, the present invention provides a fastener device for setting in a concrete floor, wall or column, the device having:

a) a body having a distal end and a facing end;

b) a bore extending at least partially through the body from the facing end towards or to the distal end, the bore being adapted to receive and support a utilities support means; and

c) attachment means for attaching the device to a formwork prior to a concrete pour such that the facing end of the device is located adjacent to or near a surface of the formwork to which the device is attached.

The body may be tapered. The body is suitably tapered downwardly in a direction from the distal end to the facing end.

The body may include one or more fastening apertures which facilitate fastening of the device to the formwork by nails, screws, clouts or the like.

The one or more fastening apertures may pass through the distal end of the device. In this embodiment, the fastening apertures may open into the bore. The one or more fastening apertures may be coaxial with the bore.

The body may include a flange at the facing end. The flange may include one or more fastening apertures. The flange assists in positioning and stabilising the device on the formwork.

The body may also include a further flange located away from the facing end. Suitably, the device may include a further flange located at the distal end. The further flange may assist in keying the device into the concrete to thereby more firmly retain the device in the concrete after the concrete pour.

The fastening means may comprise one or more barbs, spikes or projections on the facing end of the device for temporarily securing the body to the formwork. The barbs, spikes or projections may include a region of reduced thickness or a region of weakness to enable the barbs, spikes or projections to be sheared or otherwise removed from the device when removing the formwork or after removal of the formwork.

The attachment means may comprise a plug or grommet for attaching to the formwork, said plug or grommet being adapted to be received in the bore of the device. In this embodiment, the plug or grommet is attached to the formwork and the device placed over the plug or grommet such that the plug or grommet extends into the bore. This acts to retain the fastening device on the plug or grommet. After pouring the concrete, the plug or grommet may be removed from the bore (either when the formwork is removed or after the formwork is removed). In this embodiment, the attachment means for attaching the plug or grommet to the formwork may extend through the plug of grommet or it may extend through the plug or grommet and the device.

The bore of the device is adapted to receive and support a utilities support device or a fixture, such as a light fitting. The bore is advantageously a threaded bore so that the utilities support means or fixture can be threadably retained in the bore. However, it will be appreciated that other support and retaining mechanisms may be used. For example, the bore and utilities support means or fixtures may have a complementary bayonet-type fitting or may be retained together by a friction fit arrangement.

According to a further aspect of the present invention, there is provided a method of setting a fastener device as aforesaid in a concrete floor, wall or column of a structure, the method comprising the steps of:

(a) securing the device to a formwork

(b) pouring concrete, and

(c) stripping the formwork so that direct access is available to the facing end and threaded bore of the device.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present invention will now be described by way of example with reference to the accompanying drawings, in which:

FIGS. 1 and 2 are perspective and sectional drawings respectively of a fastener device according to one embodiment of the present invention;

FIG. 3 is a side view of the fastener device of FIGS. 1 and 2 fixed to an adjacent face of a formwork;

FIGS. 4 and 5 are sectional and perspective views of a tool for fitting the fasteners of FIGS. 1 and 2 to a formwork;

FIGS. 6 and 7 are perspective and sectional views of another form of fastening device according to the present invention;

FIGS. 8 and 9 are perspective and side views of an insert for the fastening device of FIGS. 6 and 7;

FIG. 10 is a side view of the fastener device of FIGS. 6 and 7 fixed to the adjacent face of a formwork;

FIGS. 11 and 12 are side views of a tool for removing the insert of FIGS. 8 and 9 from the main body of the fastener of FIGS. 6 and 7;

FIGS. 13 to 15 are sectional drawings showing further possible forms of fastener devices in accordance with the present invention;

FIG. 16 is a side sectional view of a fastened device in accordance with the further embodiment of the present invention;

FIG. 16A is a plan view of the device shown in FIG. 16;

FIG. 17 is a side sectional view of a device in accordance with another embodiment of the present invention;

FIG. 17A is a plan view of the device shown in FIG. 17;

FIG. 18 is a side view, in cross section, showing a device in accordance with another embodiment of the present invention being used in conjunction with a bar chair for use in supporting reinforcing prior to a concrete pour;

FIG. 19 shows a further embodiment of the present invention for use with a bar chair;

FIG. 19A is a plan view of the device shown in FIG. 19;

FIG. 20 shows a sectional view of a typical device in accordance with the present invention set in concrete; and

FIG. 21 shows a sectional view of a further embodiment of the present invention used for securement of light weight fixtures and fittings.

DETAILED DESCRIPTION OF THE DRAWINGS

It will be appreciated that the attached drawings are provided for the purpose of illustrating preferred embodiments of the present invention. It is to be understood that the invention should not be considered to be limited to the features shown in the attached drawings.

FIGS. 1 to 3 show a device 10 in accordance with one embodiment of the present invention. The device 10 shown in FIGS. 1-3 comprises a tapered body 11 having a distal end 12 and a facing end 13. As can best be seen from FIG. 2, tapered body 11 tapers downwardly from the distal end 12 towards the facing end 13. In this fashion, the diameter of the body at the distal end 12 is larger than the diameter of the body at the facing end 13. This assists in keying the device 10 into the concrete after it has been poured and allowed to set.

The body 11 includes a bore 14. The bore 14 is adapted to receive a utility support means or to receive fixtures or fittings. As shown in FIGS. 1 and 2, the bore 14 is a threaded bore. Threaded bore 14 extends from the facing end 13 towards the distal end 12. As clearly shown in FIG. 2, the bore 14 of the device 10 shown in FIGS. 1-3 does not extend all the way through the device.

The distal end of the body 111 is provided with a peripheral flange 16. Peripheral flange 16 extends outwardly from the facing end 13 of the body. Peripheral flange 16 assists in stabilising the device when it is secured to the formwork and when it is embedded in the concrete.

In order to attach the device 10 to the formwork, the device 10 is provided with attachment means generally indicated by arrow 15. In particular, attachment means 15 comprise a plurality of spaced barbs 17 which extend from the top face of the flange 16. Spaced barbs 17 are able to be driven into the formwork prior to the concrete pour to enable the device 10 to be attached to the formwork.

The barbs 17 shown in FIGS. 1-3 are of a generally triangular cross-section and include waisted portions 18 at their base to facilitate ready removal of the barbs when the formwork is removed following pouring of concrete and setting of the concrete. It will be appreciated that the wasted portions comprise regions of weakness to thereby allow ready removal of the barbs after the formwork has been stripped.

FIG. 3 shows a device 10 as illustrated in detail in FIGS. 1 and 2 attached to a formwork 20 for a concrete pour. As can be seen, the facing end 13 of the device 10 abuts the inner surface of the formwork 20 when the device 10 is attached to the formwork 20. If desired, a gasket may be placed between the inner surface of the formwork 20 and the facing end 13 of the device 10 in order to ensure that concrete slurry does not enter the bore 14 during the concrete pour.

The attachment of the device 10 shown in FIGS. 1-3 to the formwork 20 may be facilitated by an impact tool, such as a hammer or by using a tool 21 as illustrated in FIGS. 4 and 5. The tool 21 comprises an elongate bar 22 having a central bore 23 into which an impact rod 24 is fitted. Impact rod 24 may be telescopically moved inside bore 23.

The central bore 14 has a complementary shaped cavity 25 formed in a lower end thereof. Cavity 25 is shaped to receive the device 10 shown in FIGS. 1-3.

In use of the tool 21 shown in FIGS. 4 and 5, a fastening device 10 is positioned in cavity 25 (see FIG. 4). The tool 21 is then placed such that end 26 abuts the inner surface of the formwork 20. Impact rod 24 is then used to drive the barbs 17 of device 10 into the formwork 20.

FIGS. 6-10 show a further embodiment of the present invention. The device 30 shown in FIGS. 6 and 7 includes a body 31 of tapered external shape. The body 31 includes a distal end 32 and a facing end 33. As with a device shown in FIG. 1, the body 30 tapers downwardly from the distal end to the facing end.

The device 30 also includes a peripheral flange 34 at its facing end.

The body 31 is also provided with a bore 35. Bore 35 comprises a threaded bore.

As can be seen by comparing FIGS. 6 and 7 with FIGS. 1-3, the device 30 shares a number of similarities with a device 10. However, the device 30 does not include the barbs 17 of the device 10 shown in FIGS. 1-3. Rather, the device 30 utilises a different attachment means.

FIGS. 8 and 9 show the attachment means for use with conjunction with the fastening device 30. The attachment means shown in FIGS. 8 and 9 includes a threaded plug 36. Threaded plug 36 has an external thread that mates with the thread of threaded bore 35. Threaded plug 36 includes a through hole 37 that extends completely through the body of plug 36. The facing end 38 of plug 36 is formed with a channel 39. Channel 39 is adapted to receive the head of a screwdriver or similar driving means. It will be appreciated that the channel 39 may be replaced with other suitable arrangements that allow for the plug 36 to be screwed and unscrewed, for example, a Phillips head fitting.

In order to attach the fastening device 30 shown in FIGS. 6 and 7 to a formwork, a plug 36 is positioned adjacent an inner surface 40 of formwork 41. A nail, screw or similar fastener 42 is inserted through hole 39 and the nail, screw or similar fastener is attached to the formwork 41. For example, if a nail is used, a hammer is used to drive the nail into the formwork 41. This attaches the threaded plug 36 to the formwork. The fastening device 30 can then be attached to the threaded plug 36 by screwing the fastening device 30 onto the threaded plug 36. This arrangement is shown in FIG. 10.

Once the concrete has been poured and allowed to set, the formwork is stripped from the concrete. The threaded plug 36 can then be removed from the fastening device 30 by use of a suitable apparatus. For example, a screwdriver may be used. However, it is preferred that the tool illustrated in FIGS. 11 and 12 is used to remove the threaded plug 36 from the embedded fastening device 30. The tool 45 shown in FIGS. 11 and 12 comprises an elongate bar 46 having a cross-bar type handle 47. One end of the tool 45 is provided with prongs 48 that are received in channel 39 of threaded plug 36. As best shown in FIG. 11, a gap 49 exists between the prongs 48. Gap 49 opens up into a bore 50 in elongate bar 46. Gap 49 and bore 50 are adapted to receive the end of the nail or screw 42 that protrudes beyond the facing end of the threaded plug 36. In this fashion, prongs 48 can engage channel 39 to thereby enable the threaded plug 36 to be unscrewed from the threaded bore 35 of fastening device 30.

FIGS. 13 to 15 show further embodiments of the present invention. In the embodiment shown in FIG. 13, the fastening device 60 comprises a tapered body 61 having a distal end 62 and a facing end 63. The body 61 is provided with a bore 64 extending into the body from the facing end 63. As can be seen from FIG. 13, the fastening device 60 differs from the fastening device as shown in FIGS. 1-10 in that it does not include a flange at the facing end.

In order to secure the fastening device 60 to the formwork 65, a T-shaped bush or grommet 66 is used. The T-shaped bush or grommet 66 has a lower face 67 that is placed into abutment with an inner surface of the formwork 65. The grommet or bush 66 includes an upwardly extending portion 68 that, in use, extends into the bore 64 of the fastening device 60.

The grommet or bush 66 is fastened to the formwork 65 by use of a nail 69.

The portion 68 of the bush or grommet 66 that extends into bore 64 is suitably externally threaded so that it mates with an internal thread on bore 64 to thereby affix the fastening device 60 to the bush or grommet.

The bush or grommet 66 may be moulded or fabricated from a resilient material, such as nylon, plastics or rubber.

After the concrete has been poured and allowed to set, the formwork 65 is stripped and grommet 66 removed from the bore 64. It will be appreciated from FIG. 13 that the facing end 63 of the device 60 is positioned inwardly from an outer surface of the poured concrete.

FIG. 14 shows a generally similar embodiment to that shown in FIG. 13. For convenience, like features will be described by like reference numerals and need not be described further. The device shown in FIG. 14 differs from that shown in FIG. 13 in that the portion 68 a of the grommet or bush 66 that extends into the bore 64 has a plain outer surface and is a push fit into the bore 64 of the fastener 60. In this embodiment, the bore 64 may not need to be a threaded bore.

FIG. 15 also shows a similar embodiment to that shown in FIGS. 13 and 14 and for convenience like features will be denoted by like reference numerals. The embodiment shown in FIG. 15 differs in that the bush or grommet 66 is nailed to the formwork by a nail 69 having two enlarged heads 70, 71. Enlarged head 70 of nail 69 bears against the bush or grommet 66 whilst the enlarged head 71 bears against bottom edge of the bore 64.

In the embodiment shown in FIGS. 13 to 15, the flange of the grommet 66 that abuts the inner surface of the formwork 65 may be tacky or provided with an adhesive to assist with stability during a concrete pour. The bush or grommet 66 may also be provided with a screwdriver head channel (not shown) on their bottom edges. After a concrete pour and upon stripping of the formwork 65, the nails and grommets can be removed using conventional tools such as claw hammers and screwdrivers.

FIGS. 16 and 16A show a further embodiment in accordance with the present invention. The fastening device 70 shown in FIGS. 16 and 16A comprises a body 71 having a distal end 72 and a facing end 73. The body includes an internal bore 74 that extends from the facing end toward the distal end. The facing end 73 of the body is provided with a flange 75. Flange 75 includes fastening apertures 76 therein. Fastening apertures 76 are adapted to receive a nail 77 or similar fastening devices. A gasket 78 is interposed between the facing end 73 or the fastening device 70 and the formwork 79 to which the fastening device 70 is to be attached. The gasket 78 is suitably a rubber gasket or a fibre gasket.

In use of the device 70 shown in FIG. 16, the device is placed such that the lower side of gasket 78 abuts an inner surface of formwork 79. Nails 77 are then driven through the fastening apertures 76 to thereby secure the device 70 to the formwork 75.

After the concrete has been poured and allowed to set, the formwork 79 is stripped. The protruding ends of nails 77 may then be removed to provide a clean finish.

As shown in FIG. 16, the distal end 72 of the fastening device 70 is provided with an enlargement 80 which assists in keying the device 70 into the set concrete.

The fastening device shown in FIGS. 17 and 17A is similar to that shown in FIGS. 16 and 16A and for convenience, like reference numerals will be used to denote like parts. These like parts need not be described further. The embodiment shown in FIGS. 17 and 17A differs from that shown in FIGS. 16 and 16A in that the device 70 is fixed to the formwork 79 by a fixing means such as a screw, nail or clout 81 that passes through an aperture 82 formed in the distal end 72 of the fastening device 70. In order to prevent concrete entering the bore 74 via aperture 82, a further gasket 83 may be positioned between the head of fastening device 81 and the fastening device 70.

In FIG. 18, a device similar to the device 70 shown in FIG. 17 is used. Again, like reference numerals will be used to denote like parts. In the device shown in FIG. 18, the fixing means 81 also fixes a bar chair 84 to the fastening means 70. Bar chair 84 is used to support a reinforcing bar 85 as will be well known to persons skilled in the art.

In FIGS. 19 and 19A, an alternative embodiment of the fastening device in accordance with the present invention for use with the bar chair is illustrated. Again, like reference numerals will be used to denote like parts. In FIGS. 19 and 19A, the bar chair 84 is provided with a grate 86 which supports the device 70 in position relative to the formwork 79.

FIG. 20 shows a device that is generally similar to that shown in FIGS. 6-10 after the concrete 100 which has been poured around the device 30 has set. As can be seen from FIG. 20, the formwork 41 has been removed and the threaded plug 36 removed from the bore 35. Thus, the fastening device 30 is embedded in the concrete 100 and threaded bore 35 is open and ready to receive a utilities support means or a fixture or fitting.

FIG. 21 shows a further embodiment of the present invention. The device of FIG. 19 includes a plastic insert 110 having a distal end 111 and a facing end 112. A bore 113 is provided in the plastic insert 110. The fastening device 110 shown in FIG. 21 may be used for supporting light weight objections, such as light fittings.

In order to attach the fastening device 110 to the formwork, a screw 114 may be used.

Although not shown in the figures, the fastening device as in accordance with the present invention may be provided with scalloped distal ends so that they can also function as a nest or cradle for reinforcement bars.

The present invention eliminates the difficulties associated with having to drill holes in concrete structures to provide support for utilities supports or fixtures. The amount of time spent up ladders or scaffolding is reduced, the generation of dust and noise is reduced and problems associated with weakening or damaging concrete surfaces and drilling into unseen steel reinforcement is reduced or avoided.

Those skilled in the art will appreciate that the present invention may be subject to variations and modifications other than those specifically described. It is to be understood that the present invention encompasses all such variations and modifications that fall within its spirit and scope. 

1. A fastener device for setting in a concrete floor, wall or column, the device having: a) a body having a distal end and a facing end; b) a bore extending at least partially through the body from the facing end towards or to the distal end, the bore being adapted to receive and support a utilities support means; and c) attachment means for attaching the device to a formwork prior to a concrete pour such that the facing end of the device is located adjacent to or near a surface of the formwork to which the device is attached.
 2. A fastening device as claimed in claim 1 wherein the body includes one or more fastening apertures which facilitate fastening of the device to the formwork by nails, screws, clouts or the like.
 3. A fastening device as claimed in claim 2 wherein the one or more fastening apertures pass through the distal end of the device.
 4. A fastening device as claimed in claim 3 wherein the fastening apertures open into the bore.
 5. A fastening device as claimed in claim 1 wherein the body includes a flange at the facing end.
 6. A fastening device as claimed in claim 5 wherein the flange includes one or more fastening apertures
 7. A fastening device as claimed in claim 1 wherein the body includes a further flange located away from the facing end.
 8. A fastening device as claimed in claim 7 wherein the further flange is located at the distal end of the device.
 9. A fastening device as claimed in claim 1 wherein the body is tapered.
 10. A fastening device as claimed in claim 9 wherein the body is tapered downwardly in a direction from the distal end to the facing end.
 11. A fastening device as claimed in claim 1 wherein the fastening means comprises one or more barbs, spikes or projections on the facing end of the device for temporarily securing the body to the formwork.
 12. A fastening device as claimed in claim 11 wherein the barbs, spikes or projections include a region of reduced thickness or a region of weakness to enable the barbs, spikes or projections to be sheared or otherwise removed from the device when removing the formwork or after removal of the formwork.
 13. A fastening device as claimed in claim 1 wherein the attachment means comprises a plug or grommet for attaching to the formwork, said plug or grommet being adapted to be received in the bore of the device.
 14. A fastening device as claimed in claim 13 wherein the attachment means for attaching the plug or grommet to the formwork extends through the plug or grommet, or extends through the plug or grommet and the device.
 15. A fastening device as claimed claim 1 wherein the bore is a threaded bore.
 16. A method of setting a fastener device as claimed in claim 1 in a concrete floor, wall or column of a structure, the method comprising the steps of: (a) securing the device to a formwork (b) pouring concrete, and (c) stripping the formwork so that direct access is available to the facing end and threaded bore of the device.
 17. A fastening device substantially as hereinbefore described with reference to the accompanying figures.
 18. A method of setting a fastening device substantially as hereinbefore described with reference to the accompanying drawings. he film-forming gas to the object cleared of organic substances to form a thin film on the object. 